ENGINE LUBRICATION SYSTEM

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1 B ENGINE A SECTION ENGINE LUBRICATION SYSTEM LU C D CONTENTS E PRECAUTIONS... 2 Precautions for Liquid Gasket... 2 LIQUID GASKET APPLICATION PROCEDURE... 2 PREPARATION... 3 Special Service Tools... 3 Commercial Service Tools... 3 LUBRICATION SYSTEM... 4 Lubrication Circuit... 4 System Chart... 5 ENGINE OIL... 6 Inspection... 6 ENGINE OIL LEVEL... 6 ENGINE OIL APPEARANCE... 6 ENGINE OIL LEAKAGE... 6 OIL PRESSURE CHECK... 7 Changing Engine Oil... 8 OIL FILTER... 9 Removal and Installation... 9 REMOVAL... 9 INSTALLATION... 9 INSPECTION AFTER INSTALLATION... 9 OIL COOLER Removal and Installation REMOVAL INSPECTION AFTER REMOVAL INSTALLATION INSPECTION AFTER INSTALLATION OIL PUMP Removal and Installation REMOVAL INSTALLATION INSPECTION AFTER INSTALLATION Disassembly and Assembly DISASSEMBLY INSPECTION AFTER DISASSEMBLY ASSEMBLY SERVICE DATA AND SPECIFICATIONS (SDS) Standard and Limit OIL PRESSURE OIL CAPACITY (APPROXIMATE) OIL PUMP REGULATOR VALVE F G H I J K L M LU-1

2 PRECAUTIONS PRECAUTIONS Precautions for Liquid Gasket LIQUID GASKET APPLICATION PROCEDURE 1. Remove old liquid gasket adhering to the liquid gasket application surface and the mating surface, Using scraper. Remove liquid gasket completely from the groove of the liquid gasket application surface, bolts, and bolt holes. 2. Thoroughly clean the mating surfaces and remove adhering moisture, grease and foreign materials. PFP:00001 EBS00NLJ PBIC0003E 3. Attach liquid gasket tube to Tool. Tool number : WS ( ) Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-46, "Recommended Chemical Products and Sealants". 4. Apply liquid gasket without breaks to the specified location with the specified dimensions. If there is a groove for the liquid gasket application, apply liquid gasket to the groove. WBIA0567E As for the bolt holes, normally apply liquid gasket inside the holes. Occasionally, it should be applied outside the holes. Make sure to read the text of service manual. Within five minutes of liquid gasket application, install the mating component. If liquid gasket protrudes, wipe it off immediately. Do not retighten nuts or bolts after the installation. After 30 minutes or more have passed from the installation, fill engine oil and engine coolant. If there are specific instructions in this manual, observe them. SEM159F LU-2

3 PREPARATION PREPARATION Special Service Tools The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name Description PFP:00002 EBS00NLK A LU ST (J ) Oil pressure gauge Measuring oil pressure Maximum measuring range: 2,452 kpa (25 kg/cm 2, 356 psi) C D NT050 ST (J ) Hose Adapting oil pressure gauge to oil pan (upper) E F KV (J-38956) Oil filter wrench S-NT559 Removing oil filter a: 64.3 mm (2.531 in) G H S-NT375 I WS ( ) Tube presser Pressing the tube of liquid gasket J K NT052 Commercial Service Tools EBS00NLL L Tool name Description Power tool Loosening nuts and bolts M PBIC0190E Deep socket Removing and installing oil pressure sensor a: 24 mm (0.94 in) PBIC2072E LU-3

4 LUBRICATION SYSTEM LUBRICATION SYSTEM Lubrication Circuit PFP:15010 EBS00NLM PBIC2821E LU-4

5 LUBRICATION SYSTEM System Chart EBS00NLN A LU C D E F G H PBIC2822E I J K L M LU-5

6 ENGINE OIL Inspection ENGINE OIL PFP:KLA92 EBS00NLO ENGINE OIL LEVEL Before starting the engine make sure the vehicle is parked on a flat and level surface, then check the oil level. If the engine is already running, turn it off and allow 10 minutes before checking. 1. Pull out oil level gauge and wipe it clean. 2. Insert oil level gauge and make sure the engine oil level is within the range as indicated on gauge. 3. If the engine oil is out of range, add oil as necessary. PBIC2823E ENGINE OIL APPEARANCE Check engine oil for white milky or excessive contamination. If engine oil becomes milky, it is highly probable that it is contaminated with engine coolant. Repair or replace damaged parts. ENGINE OIL LEAKAGE Check for oil leakage around the following areas: Oil pans (lower and upper) Oil pan drain plug Oil pressure sensor Oil filter Oil cooler Water pump cover Chain tensioner cover Intake valve timing control cover and intake valve timing control solenoid valve Mating surface between cylinder block and cylinder head Mating surface between lower cylinder block and cylinder block Mating surface between cylinder head and rocker cover Mating surface between front timing chain case and rear timing chain case Mating surface between rear timing chain case and cylinder head Mating surface between rear timing chain case and cylinder block Mating surface between rear timing chain case and lower cylinder block Mating surface between rear timing chain case and oil pan (upper) Crankshaft oil seals (front and rear) Oil level gauge guide Camshaft position sensor (PHASE) LU-6

7 ENGINE OIL OIL PRESSURE CHECK WARNING: Be careful not to burn yourself, as engine oil may be hot. Oil pressure check should be done in Parking position (A/T models). 1. Check engine oil level. Refer to LU-6, "ENGINE OIL LEVEL". 2. Remove undercover with power tool. 3. Disconnect oil pressure sensor harness connector. 4. Disconnect harness connector at oil pressure sensor, and remove oil pressure sensor. Do not drop or shock oil pressure sensor. A LU C D E LBIA0424E F 5. Install Tools. Tool numbers : ST (J ) : ST (J ) G H I 6. Start engine and warm it up to normal operating temperature. 7. Check oil pressure with engine running under no-load. NOTE: When engine oil temperature is low, engine oil pressure becomes high. Engine oil pressure [Engine oil temperature at 80 C (176 F)] Engine speed rpm Approximate discharge pressure kpa (kg/cm 2, psi) Idle speed More than 98 (1.0, 14) 2,000 More than 294 (3.0, 43) WBIA0571E J K L M If difference is extreme, check oil passage and oil pump for oil leaks. 8. After the inspections, install oil pressure sensor as follows: a. Remove old liquid gasket adhering to oil pressure sensor and engine. b. Apply liquid gasket and tighten oil pressure sensor to the specification. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-46, "Recommended Chemical Products and Sealants". Oil pressure sensor torque : 14.7 N m (1.5 kg-m, 11 ft-lb) c. After warming up engine, make sure there is no leakage of engine oil with running engine. LU-7

8 Changing Engine Oil ENGINE OIL WARNING: Be careful not to burn yourself, as engine oil may be hot. Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct skin contact with used engine oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible. 1. Warm up engine, put vehicle on flat and level surface then check for engine oil leakage from engine components. Refer to LU-6, "ENGINE OIL LEAKAGE". 2. Stop engine and wait for 10 minutes. 3. Loosen oil filler cap and then remove drain plug. 4. Drain engine oil. 5. Install drain plug with new washer. Refer to EM-26, "OIL PAN AND OIL STRAINER". Be sure to clean drain plug and install with new washer. Oil pan drain plug : 34.3 N m (3.5 kg-m, 25ft-lb) 6. Refill with new engine oil. Engine oil specification and viscosity: Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS". Engine oil capacity (Approximate): Drain and refill With oil filter change 5.1 (5 3/8, 4-1/2) Without oil filter change 4.8 (5-1/8, 4-1/4) Dry engine (Overhaul) 6.3 (6-5/8, 5-1/2) Unit: EBS00NLP (US qt, Imp qt) When filling engine oil, do not pull out oil level gauge. The refill capacity depends on the engine oil temperature and drain time. Use these specifications for reference only. Always use oil level gauge to determine the proper amount of engine oil in engine. 7. Warm up engine and check area around drain plug and oil filter for oil leakage. 8. Stop engine and wait for 10 minutes. 9. Check the engine oil level. Refer to LU-6, "ENGINE OIL LEVEL". LU-8

9 OIL FILTER OIL FILTER Removal and Installation REMOVAL 1. Remove oil filter access in undercover. 2. Remove the oil filter using Tool. Tool number : KV (J-38956) Oil filter is provided with relief valve. Use Genuine NIS- SAN Oil Filter or equivalent. Be careful not to get burned when engine and engine oil may be hot. When removing, prepare a shop cloth to absorb any engine oil leakage or spillage. Do not allow engine oil to adhere to drive belts. Completely wipe off any engine oil that adheres to engine and vehicle. INSTALLATION 1. Remove foreign materials adhering to oil filter installation surface. 2. Apply engine oil to the oil seal circumference of new oil filter. PFP:15208 EBS00NLQ LBIA0425E A LU C D E F G H I 3. Screw oil filter manually until it touches the installation surface, then tighten it by 2/3 turn. Or tighten to specification. Oil filter: : 17.7 N m (1.8 kg-m, 13 ft-lb) SMA010 J K L M SMA229B INSPECTION AFTER INSTALLATION 1. Check the engine oil level. Refer to LU-6, "ENGINE OIL LEVEL". 2. Start engine, and check there are no leaks of engine oil. 3. Stop engine and wait for 10 minutes. 4. Check the engine oil level and add engine oil. Refer to LU-6, "ENGINE OIL LEVEL". LU-9

10 OIL COOLER OIL COOLER Removal and Installation PFP:21305 EBS00NLR WBIA0572E 1. Water connector 2. Water hose 3. Water pipe 4. Oil pan (upper) front side 5. O-ring 6. Relief valve 7. Oil cooler 8. Oil filter 9. Connector bolt WARNING: Be careful not to get burn yourself, as engine oil and engine coolant are hot. REMOVAL NOTE: When removing oil cooler only, step 1 is unnecessary. 1. Drain engine coolant from radiator and cylinder block. Refer to CO-9, "ENGINE COOLANT" and EM-108, "DISASSEMBLY". NOTE: Perform this step when removing water pipes. 2. Remove oil filter. Refer to LU-9, "Removal and Installation". Do not spill engine oil on drive belts. 3. Disconnect water hoses from oil cooler. When removing oil cooler only, pinching water hoses near oil cooler to prevent engine coolant spilling. Perform this step when engine is cold. Do not spill engine coolant on drive belts. 4. Remove connector bolt, and remove oil cooler. LU-10

11 OIL COOLER Do not spill engine oil to rubber parts such as drive belts and engine mounting insulator. 5. Remove water pipes, as necessary. INSPECTION AFTER REMOVAL Oil Cooler Check oil cooler for cracks. Check oil cooler for clogging by blowing through engine coolant inlet. If necessary, replace oil cooler. Relief Valve Check relief valve for movement, cracks and breaks by pushing the ball. If replacement is necessary, remove relief valve by prying it out using a suitable tool. Install a new relief valve in place by tapping it in. INSTALLATION Installation is in the reverse order of removal, paying attention to the following. Make sure that no foreign objects are adhering to the installation planes of oil cooler and oil pan (upper). Tighten connector bolt after aligning cutout on oil cooler with protrusion on oil pan (upper) side. Connector bolt torque : 49 N m (5.0 kg-m, 36 ft-lb) A LU C D E F G H PBIC2825E INSPECTION AFTER INSTALLATION 1. Check the engine oil level and the engine coolant level, and add engine oil and engine coolant. Refer to LU-6, "ENGINE OIL LEVEL" and CO-9, "ENGINE COOLANT". 2. Start engine, and make sure that there are no leaks of engine oil or engine coolant. 3. Stop engine and wait for 10 minutes. 4. Check the engine oil level and the engine coolant level again. Refer to LU-6, "ENGINE OIL LEVEL" and CO-9, "ENGINE COOLANT". I J K L M LU-11

12 OIL PUMP OIL PUMP Removal and Installation PFP:15010 EBS00NLS 1. Oil pump body 2. Oil pump outer rotor 3. Oil pump inner rotor 4. Oil pump cover 5. Regulator valve plug 6. Regulator valve spring 7. Regulator valve spring 8. Regulator valve REMOVAL 1. Remove oil pans (lower and upper). Refer to EM-26, "Removal and Installation". 2. Remove front timing chain case and timing chain (primary). Refer to EM-54, "Removal and Installation". 3. Remove oil pump assembly. INSTALLATION Installation is in the reverse order of removal, paying attention to the following. When installing, align crankshaft flat faces with inner rotor flat faces. INSPECTION AFTER INSTALLATION 1. Check the engine oil level. Refer to LU-6, "ENGINE OIL LEVEL". 2. Start engine, and check there are no leaks of engine oil. 3. Stop engine and wait for 10 minutes. 4. Check the engine oil level and add engine oil. Refer to LU-6, "ENGINE OIL LEVEL". Disassembly and Assembly DISASSEMBLY 1. Remove oil pump cover. 2. Remove oil pump inner rotor and oil pump outer rotor from oil pump body. 3. After removing regulator valve plug, remove regulator valve springs and regulator valve. PBIC2826E EBS00NLT LU-12

13 OIL PUMP INSPECTION AFTER DISASSEMBLY Oil Pump Clearance Measure the clearance with feeler gauge. Clearance between oil pump outer rotor and oil pump body (position 1 ) Standard Tip clearance between oil pump inner rotor and oil pump outer rotor (position 2 ) Standard : mm ( in) : mm ( in) A LU C D PBIC2827E Measure the clearance with feeler gauge and straightedge. Side clearance between oil pump inner rotor and oil pump body (position 3 ) Standard Side clearance between oil pump outer rotor and oil pump body (position 4 ) Standard : mm ( in) : mm ( in) E F G PBIC2828E H Calculate the clearance between oil pump inner rotor and oil pump body as follows: OIL PUMP BODY INNER DIAMETER Measure the inner diameter of oil pump body with inside micrometer. (position 5 ) OIL PUMP INNER ROTOR OUTER DIAMETER Measure the outer diameter of protruded portion of oil pump inner rotor with micrometer. (position 6 ) I J K L PBIC0821E OIL PUMP INNER ROTOR TO OIL PUMP BODY CLEARANCE (Clearance) = (Oil pump body inner diameter) (Oil pump inner rotor outer diameter) M Standard : mm ( in) If measured/calculated values are out of the standard, replace oil pump assembly. LU-13

14 OIL PUMP Regulator Valve Clearance (Clearance) = (Valve hole diameter) (Regulator valve outer diameter) Standard : mm ( in) If the calculated value is out of the standard, replace oil pump assembly. Coat regulator valve with engine oil. Make sure that it falls smoothly into valve hole by its own weight. ASSEMBLY Note the following, and assemble in the reverse order of disassembly. Install oil pump inner rotor with the groove faced and oil pump outer rotor with the punch mark to oil pump cover side. PBIC2829E PBIC2830E LU-14

15 SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) Standard and Limit OIL PRESSURE *: Engine oil temperature at 80 C (176 F) OIL CAPACITY (APPROXIMATE) OIL PUMP REGULATOR VALVE Engine speed rpm Approximate discharge pressure* kpa (kg/cm 2, psi) Idle speed More than 98 (1.0, 14) 2,000 More than 294 (3.0, 43) Drain and refill With oil filter change 5.1 (5-3/8, 4-1/2) Without oil filter change 4.8 (5-1/8, 4-1/4) Dry engine (Overhaul) 6.3 (6-5/8, 5-1/2) Body to outer rotor radial clearance ( ) Inner rotor to outer rotor tip clearance ( ) Body to inner rotor side clearance ( ) Body to outer rotor side clearance ( ) Inner rotor to brazed portion of housing clearance ( ) Regulator valve to oil pump body clearance ( ) Unit: PFP:00030 EBS00NLU (US qt, Imp qt) Unit: mm (in) Unit: mm (in) A LU C D E F G H I J K L M LU-15

16 SERVICE DATA AND SPECIFICATIONS (SDS) LU-16

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